Inspection and repair of JAHNEL & KESTERMANN ASU 560 gearbox

Scope of work:

We performed an inspection and revision on gearbox of Jahnel Kestermann ASU 560.

The conversion operations consists of:

• Disassembly
• The gearbox is completely disassembled and cleaned.
• The Gear case featured a new inside and outside coating.


• Inspection
• The holes of the casing were run-in as a result of skidding bearings.
• The holes of the gearbox were bored again.
• The gearing was in poor condition. The pinion was renewed and the output gear was after a survey for bursts whirled at the shaft and minimal re-bored.


• Fabrication and assembly of new input pinion shaft
• The new shaft was modified with reference to the old one. The bearing cap with gland was replaced by a blind cover.
• All bearings, seals and loop rings were renewed.
• The packing ring, the labyrinth and the wear liner were finished and replaced.


• Installation of the gearbox
• The oil pump was inspected and cleaned together with the pipes. The conduit of the gearbox was modified.
• The gearbox is assembled and adjusted. All bolts, rings and pins were replaced.
• Oil pressure gages and temperature gageswere replaced.
• The input coupling is reprocessed. The new input pinion shaft was such machined that the fit between the clutch and the input coupling had a light shrinkage. The coupling rubbers of the coupling were renewed.
• Testing
• The output claw coupling was in a poor condition (corrosion).
• The shrinkage between the output shaft and the coupling was minimal.
• Loctite (special glue) was used during assembling of the coupling of the output shaft.
• The gearbox had set a test run at working speed for four hours.
• Two extra coatings were applied extern before the gearbox was delivered.